UNIT 6 GENERAL PRINCIPLES & PROCESS OF ISOLATION OF ELEMENTS

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1 UNIT 6 GENERAL PRINCIPLES & PROCESS OF ISOLATION OF ELEMENTS Important Points : 1. The chemical substances in the earth s crust obtained by mining are called Minerals. 2. Minerals, which act as source for metal, are called Ore. From ore metal can be obtained economically. 3. The unwanted impurities present in ore are called Gangue. 4. The entire process of extraction of metal from its ore is called Metallurgy. 5. Removal of gangue from ore is called Concentration, Dressing or Benefication of ore. 6. Concentration by Hydraulic washing is based on the difference in gravities of ore and gangue particles. 7.Concentration by Magnetic separation is based on differences in magnetic properties of ore components. If either of ore or gangue is capable of attracted by a magnet field, then such separation is carried out. 8.Concentration by Process Froth Flotation is based on the facts that sulphide ore is wetted by oil & gangue particlesa are wetted by water. 9. Concentration by Leaching is based on the facts that ore is soluble in some suitable reagent & gangue is insoluble in same reagent. e.g. Bauxite ore contains impurities of silica, iron oxide & TiO 2. The powdered ore is treated with NaOH which dissolve Al & Impurities remains insoluble in it. Al 2 O 3 +2NaOH+ 3H 2 O 2NaAl(OH) 4 ]. Na[Al(OH) 4 ]+ 2CO 2 Al 2 O 3.xH 2 O+ 2NaHCO 3 Al 2 O 3.xH 2 O + heat Al 2 O 3 + xh 2 O 10.Calcination involves heating of ore in absence of air below melting point of metal. In this process volatile impurities escapes leaving behind metal oxide. Fe 2 O 3.xH 2 O Fe 2 O 3 +xh 2 O ZnCO 3 ZnO+CO 2 CaCO 3.MgCO 3 CaO+ MgO+ 2CO 2 1. Roasting involves heating of ore in presence of air below melting point of metal in reverberatory furnace. In this process volatile impurities escapes leaving behind metal oxide and metal sulphide converts to metal oxide. 2ZnS+ 3O 2 2ZnO+2SO 2 2PbS+ 3O 2 2PbO+2SO 2 2Cu 2 S+ 3O 2 2Cu 2 O+ 2SO 2 12.Reduction of metal oxide involves heating of metal in presence of suitable reducing agent Coke or CO 13.Reactions taking place at different zones of blast furnace in extraction of iron:- (i) Zone of reduction:- Temperature range250 o C-700 o C 3Fe 2 O 3 +CO 2Fe 3 O 4 +CO 2 Fe 3 O 4 +CO 3FeO+CO 2 FeO+CO Fe+CO 2 (ii)zone of slag formation:-temperature range800 o C-1000 o C CaCO 3 CaO+CO 2 CaO+SiO 2 CaSiO 3,

2 P 4 O C 4P+10CO, Si+2CO SiO 2 +2C MnO 2 +2C Mn+2CO (iii) Zone of fusion:-temperature range1150 o C-1350 o C CO 2 +C 2CO Temperature range1450 o C-1950 o C C +O 2 CO 2 14.FLOW SHEET FOR EXTRACTION OF IRON:- Ironore(Magnetite) (Fe 3 O 4 ) (Haematite Fe 2 O 3 ) Calcination &Roasting i.e. Ore + Air +Heat Moisture,CO 2,SO 2,As 2 O 3 removed and FeO oxidized to Fe 2 O 3 Smelting of charge i.e. mixture of ore, coke & CaCO 3 takes place in long BLASTFURNACE. Following reaction take place at different zones:- Zone of reduction, Zone of slag formation, Zone of fusion.(referto point 13) Pigiron is obtained, which is re melted and cooled then cast iron is obtained 15.Pig Iron: - It contains Fe 93-95%, Carbon 2.5-5%, and Impurities 3%. 16.Cast Iron: - It contains Fe %, Carbon % Impurities 0.3%. 17.Spongy iron: - Iron formed in the zone of reduction of blast furnace is called spongy iron. It contains impurities of C, Mn, Si, etc. 18. FLOW SHEET FOR EXTRACTION OF COPPER:- Copper Pyrites CuFeS 2 Concentration is done by Froth floatation process Powdered ore + water +pine oil +air Sulphide ore in the froth Roasting in the presence of air. Following reactions take place:- S+ O2 SO 2, 4As+3O 2 2As 2 O 3, 2CuFeS 2 +O 2 Cu 2 S+2FeS+SO 2

3 in small blast furnace of a mixture of Roasted ore, coke, and silica. 2FeS+ 3O 2 2FeO + 2SO 2, FeO + SiO 2 FeSiO 3 (slag) Bessemerisation of copper matte is done in Bessemer converter in presence of air. Following reactions take place:- 2FeS+ 3O 2 2FeO+2 SO 2, FeO + SiO 2 FeSiO 3 (slag), 2Cu 2 S+ 3O 2 2Cu 2 O+2SO 2, 2Cu 2 O+2Cu 2 S 6Cu + SO 2 Melted copper is cooled, and then SO 2 is evolved. Such copper is known as BLISTER COPPER (98%Cu+2% impurities) 19.FLOW SHEET FOR EXTRACTION OF ALUMINIUM:- Bauxite Al 2 O 3.2H 2 O Concentration of ore is done by leaching.bauxite is treated with NaOH. Following reaction takes place:- Al 2 O 3 +2NaOH+ 3 H 2 O 2 Na [Al (OH) 4 ] Impurities of Fe 2 O 3,TiO 2 &SiO 2 are removed. Na[Al(OH) 4 ],then reacts with CO 2 then pure Alumina is obtained. Na[Al(OH) 4 ]+ 2CO 2 Al2O3.xH 2 O+ 2NaHCO 3 Electrolytic reduction of pure alumina takes place in iron vessel (cathode) with cryolite (Na 3 AlF 6 ) & fluorspar CaF 2. Graphite rods act as anode. Following reactions take place:- At cathode:- Al 3+ +3e Al, At Anode:- 2O 2- O 2 +4e By this process 98.8% pure Aluminum is obtained. 20.Vapour phase refining In this method, the metal is converted into its volatile compound and collected elsewhere. It is then decomposed to give pure metal. So, the two requirements are: Mond Process for Refining Nickel: In this process, nickel is heated in a stream of carbon monoxide forming a volatile complex, nickel tetracarbonyl: The carbonyl is subjected to higher temperature so that it is decomposed giving the pure metal: vanarkel Method for Refining Zirconium or Titanium: This method is very useful for removing all the oxygen and nitrogen present in the form of impurity in certain metals like Zr and Ti. The crude metal is heated in an evacuated vessel with iodine. The metal iodide being more covalent,volatilizes:

4 The metal iodide is decomposed on a tungsten filament, electrically heated to about 1800K. The pure metal is thus deposited on the filament. 21.Liquation In this method a low melting metal like tin can be made to flow on a sloping surface. In this way it is separated from higher melting impurities. 22.Chromatography method is based on selective distribution of various constituents of a mixture between two phases, a stationary phase and a moving phase. The stationary phase can be either solid or liquid on solid support. 22.Column chromatography is based on adsorption phenomenon. This method is use ful for those elements, which are available in small amounts and the impurities are not much different in chemical properties from the element to be purified. VERY SHORT ANSWER TYPE QUESTIONS (1 marks) 1. What is slag? It is easily fusible material, which is formed when gangue still present in roasted ore combines with the flux. e.g.cao (flux) + SiO2(gangue) CaSiO 3 (slag) 2. Which is better reducing agent at 983K, carbon or CO during the extraction of iron? CO, (above 983K CO being more stable & does not act as a good reducing agent but carbon does.) 3. At which temperature carbon can be used as a reducing agent forfeo? Above 1123K, carbon can reduce FeO to Fe. 4. What is the role of graphite rods in electrometallurgy of aluminium? Graphite rods act as anode, are attacked by oxygen to form CO 2 and so to be replace time to time. 5. What is the role of cryolite in electrometallurgy of aluminium? A lumina can not be fused easily because of high melting point. Dissolving of alumina in cryolite furnishes Al 3+ ions, which can be electrolysed easily. 6. What are depressants? It is possible to separate two sulphide ore by adjusting proportion of oil to water in froth flotation process by using a substance known as depressant. e.g. NaCN is used to separate ZnS and PbS. 7. Copper can be extracted by hydrometallurgy but not Zn. Why? The E 0 of Zn is lower than that of Cu thus Zinc and is place Cu 2+ ion from its solution. On other hand side to displace Zn from Zn 2+ ion,we need a more reactive metal than it. 8. Give name and formula of important ore of iron. Haematite Fe 2 O 3,Magnetite Fe 3 O 4,Iron pyrites FeS Give name and formula of important ore of Copper. Copper pyrites CuFeS 2, Malachite CuCO 3.Cu(OH) 2,Cuprite Cu 2 O. 10. Give name and formula of important ore of Zinc. Zinc blende - ZnS, Calamine- ZnCO 3,Zincite ZnO. 11.Write the principle involved in zone refining. Ans. Impurities are more soluble in melt than in the solid state. 12. Name the method used for the refining of Nickel metal Ans: Mond s Process

5 13.Why froth floatation process is used for concentration sulphide ores Ans: It is based on the preferential wetting of the ore particles by oil and the gangue particles by water. SHORT ANSWER TYPE QUESTION - (2 marks) 1. Describe the method of refining of nickel. In the Mond Process, Ni is heated in a streamof CO forming a volatile complex, which then decomposes at higher temperature to give Ni. At K: - Ni + 4CO Ni (CO) 4 At K Ni (CO) 4 Ni + 4 CO 2. What is Zone Refining?Explain with example. Zone refining is a method of obtaining a metal in very pure state. It is based on the principle that impurities are more soluble in molten state of metal than solidified state. In this method, a rod of impure metal is moved slowly over circular heater. The portion of the metal being heated melts & forms the molten zone. As this portion of the rod moves out of heater, it solidified while the impurities pass in to molten zone. The process is repeated to obtain ultra pure metaland end of rod containing impure metal cut off. 3.Write the principle of electro-refining. In this method of purification impure metal is made Anode and pure metal is made the cathode. On passing electricity, pure metal is deposited at the cathode while the impurity dissolve in solution as anode mud. E.g. electro- refining of copper:- At Cathode: Cu 2+ +2e Cu At Anode: Cu Cu 2+ +2e 4. Describe the method of refining of Zirconium and Titanium. Van Arkel process is used for obtaining ultra pure metal. The impure metal is converted into volatile compound, which then decomposes electrically to get pure metal. At850K: - Zr impure) + 2 I 2 ZrI 4 At2075K:- ZrI 4 Zr (pure) + 2 I 2 5. Write the chemical reactions involved in the extraction of metallic silver from argentile. Ans. Ag 2 S + 4NaCN 2Na [Ag(CN) 2 ] +Na 2 S 4Na 2 S + 5O 2 2Na 2 SO 4 +4NaoH +2S 2 Na [Ag (CN) 2 ] + Zn Na 2 [Zn(CN) 4 ]+ 2Ag Sod.tetracynozincate (II) 6.Explain the role of (i) Cryolite in the electrolytic reduction of alumina (ii) Carbon monoxide in the purification of nickel. Ans. (i) Cryolite lowers the melting point of mixture. Or it act as electrolyte. (ii)carbon monoxide forms a volatile complex with nickel which on heating decomposes to give pure nickel. SHORT ANSWER TYPE QUESTION - (3 marks) Q.1-Explain the following:- (i) Zinc but not copper is used for recovery of Ag fromthe complex [Ag(CN) 2 ] - (ii) Partial roasting of sulphide oreis done in the metallurgy of copper. (iii) Extraction of Cu from pyrites is difficult than that fromits oxide ore through reduction

6 Ans. (i) Zn is more powerful reducing agent in comparison to copper. Zn is also cheaper than Cu (ii)partial roasting of sulphide ore forms some oxide. This oxide then reacts with remaining sulphide ore to give copper i.e. self-reduction occurs. 2Cu 2 S+ 3O 2 2Cu 2 O+2SO 2, 2Cu 2 O+2Cu 2 S 6Cu + SO 2. (iii)though carbon is good reducing agent for oxide but it is poor reducing agent for sulphides. The reduction of metal sulphide does not have large negative value. Q.2- Explain the method for obtaining pig iron from magnetite. Extraction of iron from Magnetite takes place in following steps:- (i)concentration of ore: - Itis done by Gravity separation followed by magnetic separation process. (ii) Calcination: - It involves heating when the volatile matter escapes leaving behind metal oxide. Fe 2 O 3.xH 2 O Fe 2 O 3 +xh 2 O. (iii)roasting:-it involves heating of ore in presence of air,thus moisture, CO 2, SO 2,As 2 O 3 removed and FeO oxidized to Fe 2 O 3. (iv)smelting of roasted ore:-a mixture of ore, coke & CaCO 3 is smelted in long BLASTFURNACE. Following reaction takes place at different temperature zones:- (i) Zone of reduction: - Temperature range 250 o C-700 o C 3Fe 2 O 3 +CO 2Fe 3 O 4 +CO 2 Fe 3 O 4 +CO 3FeO+ CO 2 FeO+CO Fe+ CO 2 (ii)zone of slag formation:- Temperature range 800 o C-1000 o C CaCO 3 CaO+CO 2 CaO+SiO 2 CaSiO 3 P 4 O C 4P+10CO, SiO 2 +2C Si+2CO, MnO 2 +2C Mn+2CO (iii)zone of fusion:- Temperature range 1150 o C-1350 o C CO2+ C 2CO (iv)zone of fusion:- Temperature range 1450 o C-1950 o C C +O 2 CO 2 Thus,Pig iron is obtained from Blast Furnace. Q.3 Name the principle ore of aluminium and describe how Al is extracted fromits ore. Important ores-(i) Bauxite Al 2 O 3.xH 2 0(ii) Corrundum Al 2 O 3. Bauxite is commercially important ore of Al Extraction from Bauxite ore involves the following two stages:- (i) Purification of bauxite to get pure alumina (Al 2 O 3 ) (ii) Electrolysis of pure alumina in molten cryolite Step:-1Bauxite is treated with NaOH.Following reaction takes place:- Al 2 O 3 +2NaOH+3H 2 O 2Na[Al(OH) 4 ] Impurities of Fe 2 O 3, TiO 2 & SiO 2 are removed. Na [Al(OH) 4 ], then reacts with CO 2 then pure Alumina is obtained. Na[Al(OH) 4 ]+ 2CO 2 Al 2 O 3.xH 2 O+ 2NaHCO 3

7 Step:-2 Electrolytic reduction of pure alumina takes place in iron box (cathode) with cryolite (Na 3 AlF 6 ) & fluorspar CaF 2. Graphide rods act as anode. Following reactions take place:- At cathode: Al 3+ +3e Al, At Anode: 2O 2- O 2 + 2e - By this process 98.8 % pure Aluminum is obtained. 4. State briefly the principles which serve as basis for the following operations in metallurgy. (i) Froth-floatation process (ii)zone refining (iii) Refining by liquation Ans: (i) Froth floatation process: This process is used for the concentration of sulphide ores. For example, ores of lead, zinc and copper, because of the fact that metallic sulphides are more wetted by certain oils(pine oil) and less by water. The finely crushed ore is put into a water containing a small quantity of oil (pine oil). The mixture is then agitated by passing a blast of air through it. The froth is formed which carries the ore particles along with it to the surface leaving the impurities behind. The froth scummed off. It is then dried for the recovery of the ore particle. In this way the oreis concentrated by froth floatation process. (ii)zone Refining: This method is based on the principle that the impurities are more soluble in the melt than in the solid state of the metal. A circular mobile heater is fixed at one end of a rod of impure metal. The molten zone moves along with the heater which is moved forward. As the heater moves forward, the pure metal crystallizes out the melt and the impurities pass on into the adjacent molten zone. The process is repeated several times and the heater is moved in the same direction. At one end, impurities get concentrated. This end is cut off. This method is very useful for producing semi-conductor and other metals of very high purity e.g., germanium, silicon,boron, gallium and indium. (iii) Refining by liquation: In this method a low melting metal like tin(sn)can be made to flow on sloping surface. In this way it is separated from higher melting impurities. 5. Describe the role of (i) NaCN in the extraction of gold from gold ore. (ii) SiO 2 in the extraction of copper from copper matte. (iii) Iodine in refining of zirconium. Write chemical equations for the involved reactions. (i) Role of NaCN in the extraction of gold is to do the leaching of gold ore in the presence of the air from which gold is obtained later by replacement. 4Au(s) + SCN - (aq) + 2H 2 O + O 2 (g) 4[Au(CN) 2 ] - + 4OH - (ii) SiO 2 is added in copper matte to convert the remaining FeS, FeO to slag. FeO + SiO 2 FeSiO(slag) (iii) Iodine is heated with Zirconium to form a volatile compound which on further heating decompose to give pure zirconium as shown: Zr + 2I 2 ZrI 4 (Impure) ZrI 4 Zr + 2I 2 (Pure) 6.Describe how the following change are brought about: (i) Pig iron into steel. (ii) Zinc oxide into metallic Zinc. (iii) Impure titanium into pure titanium. Ans. (i) Pig iron converted into steel by adding carbon and some other elements. (ii)metallic zinc is obtained from zinc oxide by reduction by coke. ZnO + C Zn + CO

8 (iii) Impure titanium is heated with iodine to form volatile complex TiI 4 which on further heating to higher temperature decomposes to give pure titanium. HOTS QUESTIONS Q.1. Metals like Zn, Cu, Hg, Ag, and Pb occur in nature as sulphides rather than oxides. Why? Ans: Cations of these metals have high polarizing power and hence can polarize the bigger sulphide ion than the smaller oxide ion. Therefore their sulphides are more stable than oxides. Q.2. Why is it advantageous to convert a sulphide ore to oxide before reduction.? Ans: Standard Gibbs energy of formation of most of the sulphides are more negative than those of CS 2 and H 2 S. Therefore neither carbon nor hydrogen can reduce metal sulphides to metals. But the free energy of formation of oxides are much lower than that of SO 2. Hence oxidation of metal sulphides to metals is thermodynamically favourable. And the free energy of formation of these metal oxidises is less negative than that of CO. Hence Carbon can reduce these oxides to metals. Q.3. The oxidation of Gold by leaching with NaCN involves both oxidation and reduction. Justify. Ans: During leaching gold is first oxidized to Au + by oxygen of the air which then combines with CN - to form cyano complex. After that Zn acts as the reducing agent and reduces Au + to gold. Q.4. Cinnabar and Galena on roasting give their respective metals but zinc blende does not. Explain. Ans: On roasting all these sulphide ores are partly converted into their respective oxides. The oxides of mercury and lead are unstable, but but zinc oxide is more stable. Therefore oxides of mercury and lead bring about the reduction of their respective sulphides to the metals.but zinc oxide does not reduce ZnS to Zn metal. Q.5. Zinc and not copper is used for the recovery of Ag from [Ag(CN) 2 ] - Ans: The E o of zinc is lower than that of copper. Therefore zinc is more powerful reducing agent than copper. And zinc is cheaper than copper. VALUE BASED QUESTIONS Q1) A washer woman, while washing a miner s overalls, she noticed that sand and similar dirt fell to the bottom of the wash tub. What was peculiar, the copper bearing compounds that had come to the cloths from mines were caught in soap suds and so they come to the top. One of her client was chemistry teacher Mrs Geetha. The washer woman told her experience to Mrs Geetha who thought that the idea could be used for separating coper compounds from rocks and Earth materials on large scale. This way an invention was born. (1) Which method was invented by above experience? (2) What values were possessed by washer women? (3) What was the effect of the above invention? Ans. (i) froth-floatation process for sulphide ores of copper (ii) scientific temperament, attentive to observations, innovative mind. (iii) invention of the froth-flotation process made cooper mining profitable even from the low grade ores. World production of copper increased and the metal became cheaper.

9 Q2) In roasting, the ore is heated in regular amount of air in a furnace at a below the melting point of the metal. Metal sulphide gets converted into metal oxides and sulphur dioxide gas is formed which is an air pollutant. It also leads to the formation of the acid rain which is harmful for crops and building made up of marble. 1) Where should we have industry using roasting process in metallurgy? Give reason. 2) How can we use sulphur dioxide gas? 3) What are the uses of sulphuric acid? How can it help in national economy? Ans. (i) These industries should be away from highly populated area because air pollution due to sulphur dioxide gas is harmful for all living beings. (ii) Sulphur dioxide gas can be used for the manufacture of sulphuric acid. (iii) It is used in fertilizers, detergents and medical industries. Sulphuric acid is king of chemicals. It is used in fertilizers, petroleum refining, lead storage batteries, metallurgy, electroplating and galvanization. It is used in lot of Industries; therefore, it helps in national economy of country like India which is mainly dependent upon agriculture and industries. Q3) Gold occurs in free state in earth s crust. It is leached with dilute solution of potassium cyanide to form a soluble complex. Gold is smuggled in the form of this complex compound as it is liquid like lime water and can t be detected even by X-ray. Customs officers found it extra ordinary heavy liquid and sent into chemistry lab. (1) How will chemistry find that it contains potassium dicyanoaurate (I)? (2) Should potassium cyanide be readily available? (3) How can you prevent smuggling of gold by this process? What values are not processed by smugglers? Ans. (i) If zinc is added to gold metal will be formed. (ii) No, potassium cyanide should not be readily available. It should only be supplied to industries and research labs with permit. (iii) liquid should not be allowed to be transported without proper certification. Smugglers are enemies for the country. They are not honest and sincere about these countries.

GENARAL INTRODUCTION TO METALLURGY :Std: XI-CHEMISTRY

GENARAL INTRODUCTION TO METALLURGY :Std: XI-CHEMISTRY 1. What is matrix? The ore is generally associated with rock impurities like clay, sand etc. called gangue or matrix 2. What is mineral? The natural